Solar water heating system for insallation under any type of roofing material

ABSTRACT

A system for quickly, easily and inexpensively facilitating the attachment of various solar water heating components to the roof of a structure in a panel form generally without regard to the type of underlying roof support structure and further, which provides an upper surface upon which essentially any type of roofing material maybe installed. In a first embodiment, it is contemplated that all of the components of the invention may be provided in the form of a ‘panel’ of essentially any size such as, for example, a panel measuring 4′×4′, 4′×8′, or any other size that is convenient and workable in terms of weight and ease of installation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent Application No. 61/768,723 titled “HEATING SYSTEM FOR INSTALLATION UNDER ANY TYPE OF ROOFING MATERIAL”, filed on Feb. 25, 2013 and incorporated fully herein by reference.

TECHNICAL FIELD

The present invention relates to roofing systems and more particularly, relates to a various components that together provide a solar hot water heating system that is capable of being installed and used under almost any type of roofing material such a an asphalt roof, metal roof or the like.

BACKGROUND INFORMATION

The installation of solar hot water heating systems on a roof is not quite yet commonplace. A roof provides a relatively large area exposed to solar heat and is an ideal location for a solar collector. Currently, available roof mounted solar water heaters do suffer from several drawbacks. First, roof mounted existing solar water heaters are rather large and might be considered by some as unsightly. Secondly, the existing roof mounted solar water heating systems are not compatible with all roof types. For example, a solar water heating system designed for a metal roof will generally not be usable under or on an asphalt covered roof and vice-versa. Moreover, existing roof mounted solar water heating systems are incapable of being mounted under the roofing material thus making them essentially invisible while providing the same benefits of solar heat collection.

Accordingly, what is needed is a system which allows a solar hot water heating assembly to be mounted under any type of roofing material thereby rendering it essentially invisible while at the same time providing all of the benefits of solar heat collection and capture by the heating system.

SUMMARY OF THE INVENTION

The present invention features a system for quickly, easily and inexpensively facilitating the attachment of various solar water heating components to the roof of a structure in a panel form. The system comprises a plurality of vertical structural members, configured to be installed on an existing roof and even perhaps over an existing roofing member be it plywood, asphalt shingles, rolled asphalt material, rubber roofing, steel or metal roofing or the like. The vertical structural member is preferably in the form of a channel member having an open bottom region which allows tabs to be “punched” out of the top surface of the vertical structural member prior to installation of module components. The tabs are configured to engage with one leg of a heat transfer plate while a second leg of the heat transfer plate is configured to be fastened into the vertical structural member utilizing fastener such as a screw, nail, rivet or the like.

The invention also features a plurality of heat transfer plates. Each of the plurality of heat transfer plates includes a first end and a second end. Each heat transfer plate further includes a first generally “Z” shaped leg and a second generally “Z” shaped leg. Between the 2 “Z” shaped legs is a generally flat region that includes a partially circular channel which serves to hold a plastic, composite, PVC or other type of pipe or conduit which carries water or other liquid medium and which, by virtue of its contact with the partially circular channel, conducts and transfers solar energy in the form of heat from the heat transfer plate to the liquid medium which is circulated inside the conduit.

The system of the invention also includes a plurality of nailer members. One nailer member is located between every heat transfer plate. Each nailer is comprised of a material such as wood, composite, plastic or the like and is designed to receive fasteners for nailing or otherwise holding down a roofing product which will be installed on top of the assembly. Each nailer may also be coated or wrapped with a heat conductive material such as aluminum or the like.

The invention also features a plurality of end nailer plates. A first one of the plurality of end nailer plates is disposed proximate each first end of the each of the plurality of heat transfer plates while a second one of the plurality of end nailer plates is disposed proximate each second end of each of the plurality of heat transfer plates. Each end nailer plate includes a groove of an appropriate size and radius to accommodate an appropriate and desired bend in the conduit such that once installed, the end nailer plate provides a generally flat surface in connection with the top surface of the nailer plate and the top surface of the heat transfer plate to allow roofing material, such as asphalt roofing shingles and the like to be installed over the assembly. Each end nailer plate may also be coated or wrapped with a heat conductive material such as aluminum or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features and advantages of the present invention will be better understood by reading the following detailed description, taken together with the drawings wherein:

FIG. 1 is a cross-sectional representation of a solar water heating system panel in accordance with the teachings of the present invention;

FIG. 2 is a top/and perspective you of the end nailer member of the present invention being inserted into place; and

FIG. 3 is a top perspective view of the end nailer member and conduit in place along with a piece of roofing material partially covering the system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention features a system for quickly, easily and inexpensively facilitating the attachment of various solar water heating components to the roof of a structure in a panel form generally without regard to the type of underlying roof support structure and further, which provides an upper surface upon which essentially any type of roofing material may be installed.

In a first embodiment of the present invention, it is contemplated that all of the components of the system of the present invention (as will be described in greater detail below, may be provided assembled into the form of a “sheet” or “panel” of essentially any size such as, for example, a panel measuring 4′×4′, 4′×8′, or any other size that is convenient and workable in terms of weight and ease of installation.

Irrespective of the size of any sheet or panel, the constituent components will be the same. As shown in FIG. 1, these include a vertical structural member 10 which is designed to be installed on an existing roof and even perhaps over an existing roofing member be it plywood, asphalt shingles, rolled asphalt material, rubber roofing, steel or metal roofing or the like.

The vertical structural member 10 is preferably made of a light weight material such as extruded aluminum which helps reduce the weight of the panel. It is preferred that the vertical structural member 10 be in the form of a channel member having an approximate size of 1 inch by 1.5 inches and having an open bottom region which allows the tabs 12 to be “punched” out of the top surface of the vertical structural member 10 prior to installation of module components. The purpose of the tab 12 is to engage with one leg 14 of the heat transfer plate 16.

The second leg 18 of the heat transfer plate 16 will be fastened into the vertical structural member 10 utilizing fastener 20 such as a screw, nail, rivet or the like. The provision of multiple tabs 12 on the vertical structural member 10 allows the preassembly of the invention into panels making sure that the spacing between the heat transfer plates 16 is accurate and consistent.

The heat transfer plates 16 are preferably made of a material which is easy to bend and shape but which also is a good transmitter of heat and provides a relatively large surface area to be heated by solar energy. In the present exemplary design, the heat transfer plate 16 includes a first generally “Z” shaped leg 22 and a second generally “Z” shaped leg 24. Between the 2 “Z” shaped legs 22, 24 is a generally flat region 26 that includes a partially circular channel 28 which serves to hold a plastic, composite, PVC or other type of pipe or conduit 30 which carries water or other liquid medium and which, by virtue of its contact with the partially circular channel 28, conducts and transfers solar energy in the form of heat from the heat transfer plate 16 to the liquid medium which is circulated inside the conduit 30. The diameter of the partially circular channel 28 may be made to fit any desired conduit size.

The exemplary embodiment, the heat transfer plate 16 is approximately ¾ of an inch in height and has a base width of approximately 5 inches and a top surface width of approximately 3 inches. The shape of the heat transfer plate 16 is designed to be locked into the tab 12 on one leg while a fastener is used on the other leg. Other dimensions, shapes and sizes are contemplated by the present invention.

Located between every heat transfer plate 16 is a nailer 32. Each nailer 32 is comprised of a material such as wood, composite, plastic or the like and is designed to receive fasteners for nailing or otherwise holding down a roofing product which will be installed on top of the assembly of the present invention. Each nailer 32 may have a coating applied to its top surface 34 to make it compatible with the roofing product to be utilized. For example, a coating may be provided to the top surface 34 which is designed to receive a rubber/PVC and/or asphalt based roofing product. In addition, the nailer 32 may also be designed to accept either an exterior or interior wall product should the sheet or panel of the present invention be used on a wall or even a floor.

In a further embodiment, the nailer 32 may have a heat absorbing coating or heat absorbing wrap which is a good transmitter of heat and provides a relatively large surface area to be heated by solar energy. For example the nailer 32 may he wrapped in aluminum to make to receive fasteners for nailing or otherwise holding down a roofing product which will be installed on top of the assembly while also making it heat absorbing.

In addition to the previously mentioned components, the present invention contemplates an end nailer plate 40, FIG. 2, which includes a groove 42 of an appropriate size and radius to accommodate an appropriate and desired bend 44 in the conduit 30. Once installed, the end nailer plate 40, FIG. 3 provides a generally flat surface in connection with the top surface 34 of nailer plate 32 and the top surface 26 of heat transfer plate 16 to allow roofing material, such as asphalt roofing shingles 46 to be installed over the assembly.

In a further embodiment, the end nailer plate 40 may have a heat absorbing coating or heat absorbing wrap which is a good transmitter of heat and provides a relatively large surface area to be heated by solar energy. For example the end nailer plate 40 may be wrapped in aluminum to make to receive fasteners for nailing or otherwise holding down a roofing product which will be installed on top of the assembly while also making it heat absorbing.

Accordingly, the present invention provides a number of novel components which may be assembled into a sheet or panel, which sheet or panel can then be easily installed over almost any type of roof, and over which sheet or panel may then be installed generally any type of roofing material such as a rubberized roofing membrane, asphalt shingles, at rolled asphalt material or metal roofing. The underlying panel becomes heated by virtue of exposure to solar energy in such heat is transferred into the liquid medium circulating within the conduit located in the assembly of the invention.

Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the allowed claims and their legal equivalents. 

The invention claimed is:
 1. A panel assembly for quickly, easily and inexpensively facilitating the attachment of various solar water heating components to the roof of a structure in a panel assembly, the panel assembly comprising: a plurality of vertical structural members, each of said plurality of vertical structural members configured to be installed on an existing roof, each of said plurality of vertical structural members is in the form of a channel member having an open bottom region which allows one or more tabs to be “punched” out of a top surface of the vertical structural member prior to installation, wherein said one or more tabs are configured to engage with one leg of a heat transfer plate, while a second leg of the heat transfer plate is configured to be fastened into one of said plurality of vertical structural members utilizing one or more fasteners; a plurality of heat transfer plates, each of said plurality of heat transfer plates including a first end and a second end, each heat transfer plate further including a first generally “Z” shaped leg and a second generally “Z” shaped leg, between the 2 “Z” shaped legs is a generally flat region that includes a partially circular channel which is configured to support a conduit which carries water or other liquid medium and which, by virtue of its contact with the partially circular channel, conducts and transfers solar energy in the form of heat from the heat transfer plate to the liquid medium which is circulated inside the conduit; a plurality of nailer members, one nailer member located between every heat transfer plate, wherein each nailer member is designed to receive fasteners for nailing or otherwise holding down a roofing product which will be installed on top of the panel assembly; and a plurality of end nailer plates, a first one of said plurality of end nailer plates disposed proximate each first end of the each of said plurality of heat transfer plates, and a second one of said plurality of end nailer plates disposed proximate each second and of each of said plurality of heat transfer plates, each end nailer plate including a groove of an appropriate size and radius configured to accommodate an appropriate and desired bend in the conduit such that once installed, the end nailer plate is configured to provide a generally flat surface in connection with the top surface of the nailer plate 32 and the top surface of the heat transfer plate to allow roofing material to be installed over the panel assembly.
 2. The panel assembly of claim 1, wherein said a plurality of vertical structural members are configured to be installed over an existing roof.
 3. The panel assembly of claim 1, wherein said existing roof is constructed of a material selected from the group consisting of plywood, asphalt shingles, rolled asphalt material, rubber roofing and steel or metal roofing.
 4. The panel assembly of claim 1, wherein said one or more fasteners are selected from the group of fasteners consisting of a screw, a nail and a rivet.
 5. The panel assembly of claim 1, wherein said conduit is constructed from a material selected from the group consisting of plastic, composite, aluminum, copper and PVC.
 6. The panel assembly of claim 1, wherein each nailer member is comprised of a material selected from the group of materials consisting of wood, composite and plastic.
 7. The panel assembly of claim 1, wherein said panel assembly is configured to be installed over an existing roofing member on which has been previously installed an existing roofing material.
 8. The panel assembly of claim 7, wherein said existing roofing material is selected from the group consisting of asphalt shingles, rolled asphalt material, rubber roofing and steel or metal roofing.
 9. The panel assembly of claim 1, wherein said plurality of nailer members include a heat absorbing coating or wrap.
 10. The panel assembly of claim 9, wherein said heat absorbing coating or wrap is an aluminum wrap.
 11. The panel assembly of claim 1, wherein said plurality of end nailer plates include a heat absorbing coating or wrap.
 12. The panel assembly of claim 11, wherein said heat absorbing coating or wrap is in aluminum wrap 